I've been considering this for awhile myself, and Blue is absolutely correct. It seems to be a fairly straightforward, though involved, conversion from the research I have done. One way to make life easier on yourself would be to attempt to find a donor that is either the same, or close to the same year as your XJ for a better electronics match. And no, there was no D30 2WD version as it is a front drive axle, if you look under your 2WD XJ you'll find that we have a solid beam up front, not an actual drive axle. And no, there's no transfer case on a 2WD, this is why you'll need a transmission from a 4x4. Your 2WD transmission is a bit longer than a 4x4 trans and won't bolt up to a t-case. I say go for it and do your conversion, it's really easy to just say "Sell your XJ, buy a 4x4." but I love my XJ 2WD or not and I'm sure you do too! I wouldn't want to just give up on her and give her away, I'de rather put in the work to get her where I want her to be!

 

Winner! Those who say just sell and replace usually dont have an attachment to their current rig.

In all honesty a 4wd conversion can be done in a day by a few competent guys, and for about $500 or a tad more. Look for someone parting a driving rig. You should be able to get a trans for 200 or so, another 1-150 for a transfer, 100 for a front axle with matching gear ratio. Front shaft and a few other odds and ends.

In my case i rolled my rig almost 9 years ago and couldnt find a cheap 4wd XJ. I found a 2wd XJ for 1200 and sold off what i didnt need off the old rig.

 

What tools would I need to complete this job, I would think the hardest part would be the transmission swap because I can bolt on the T-case before I even attach the new transmission right?

I have been looking for a transfer case online, but the prices seem ridicilous. I guess thats why people always suggest junkyards.

I wouldn't have to change the rear axle correct?

 

No, no need to change the rear axle. Just make sure your rear driveshaft matches up, if not, you'll need one of those too. Mostly basic hand tools will get this job done, not to much in the way of speciealty stuff. Maybe having a transmission jack handy would help. Plenty of PB blaster for those stubborn bolts. Having a mechanically competent friend is necessary as well. Buying a T-case online would probably be more pricey than a JY, best option of all would be to score one from someone parting out a rig like OverlandXJ suggested.

 

You would be better off price wise getting the TC from a JY and rebuilding it if you were unsure of the reliability than buying a new TC.

I dont know much about 4WD but with the recent problems I am having with my XJ Sport i have been looking at rebuild kits online and they are going for under 200..not sure how much a case would be at a JY but i would think under 200 also.

 

Make sure you have the same axle gear ratio in your front end as you have in your rear axle.

 

How could I find out the axle gear ratio for the rear?

 

Jack up your rear end and spin your driveshaft count the rotations of the wheels in regards to the driveshaft that should tell ya. Most likly its a 3.55 but it could be a 3.73 or a 3.05